Composite pallet with augmented compression support, and process for manufacturing same

Abstract

Exemplary embodiments of a composite pallet with augmented compression support may comprise a pallet pulp body, a multiplicity of support foot sheathes, and a support bottom plate. The pallet pulp body may be comprised of pulp and may have an upper faceplate and a plurality of support feet disposed oppositely of the upper faceplate. A foot cavity may be defined within each support foot. Each of the support foot sheaths may envelope at least a portion of a corresponding support foot. The support bottom plate may be affixed to two or more of the support foot sheaths. A plurality of arcuate stiffener grooves may be disposed in the upper faceplate. One or more of the foot cavities may have a compression column disposed therein. Each compression column may comprise one or more column layers, a compression column block, or a combination thereof. The column layers may be nested.

What is claimed is: 
     
       1. A composite pallet with augmented compression support, the pallet comprising:
 a pallet pulp body being comprised of pulp and having an upper faceplate and a plurality of support feet disposed oppositely of the upper faceplate, a foot cavity being defined within each support foot; 
 a multiplicity of support foot sheaths, each support foot sheath enveloping at least a portion of a corresponding one of said support feet; and 
 a support bottom plate affixed to two or more of the support foot sheaths; 
 wherein the support bottom plate
 (a) has a bottom plate aperture, and 
 (b) is only affixed to support foot sheaths disposed peripherally about the pallet pulp body. 
 
 
     
     
       2. A composite pallet with augmented compression support, the pallet comprising:
 a pallet pulp body being comprised of pulp and having an upper faceplate and a plurality of support feet disposed oppositely of the upper faceplate, a foot cavity being defined within each support foot; 
 a multiplicity of support foot sheaths, each support foot sheath enveloping at least a portion of a corresponding one of said support feet; 
 a support bottom plate affixed to two or more of the support foot sheaths; and 
 a multiplicity of compression columns, each compression column being disposed within the foot cavity of a respective said support foot; 
 wherein each compression column includes a compression column block; 
 wherein each compression column includes a first column layer disposed between the compression column block and the respective foot cavity; and 
 wherein each compression column includes a second column layer disposed between the first column layer and the compression column block. 
 
     
     
       3. The composite pallet of  claim 2 , wherein each compression column includes a third column layer disposed between the first column layer and the compression column block. 
     
     
       4. A composite pallet with augmented compression support, the pallet comprising:
 a pallet pulp body being comprised of pulp and having an upper faceplate and a plurality of support feet disposed oppositely of the upper faceplate, a foot cavity being defined within each support foot; 
 a multiplicity of support foot sheaths, each support foot sheath enveloping at least a portion of a corresponding one of said support feet; 
 a support bottom plate affixed to two or more of the support foot sheaths; and 
 a multiplicity of compression columns, each compression column being disposed within the foot cavity of a respective said support foot; 
 wherein each compression column includes
 (a) a first column layer disposed within the respective foot cavity, 
 (b) second column layer disposed within the first column layer, and 
 (c) a third column layer disposed within the second column layer. 
 
 
     
     
       5. The composite pallet of  claim 4 , wherein each column layer has an open bottom. 
     
     
       6. The composite pallet of  claim 4 , wherein each column layer has a closed bottom. 
     
     
       7. The composite pallet of  claim 2 , wherein each compression column block and column layer is comprised of a material selected from the group consisting of plant fiber, synthetic fiber, metal, wood and plastic.